Modular Solar Tracker Drive Assembly for Easier Field Maintenance
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Solution Overview
Problem
Existing solar tracker drives are bulky, require complex assembly in the field, and have limited modularity, making them difficult to transport, assemble, and maintain.
Innovation Solution
A modular drive system for solar trackers that integrates a reduction gear system, gear motor, and tracker electronics into a compact assembly, allowing for simplified shipping, assembly, and maintenance, and eliminating the need for external electronics and cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the drive components (reduction gear, gear motor, electronics) are supplied independently and assembled in the field, then each component can be optimized separately, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the reduction gear system, gear motor, and tracker electronics into a single integrated modular drive assembly. This merging eliminates the need for separate field assembly of multiple independent components, simplifying the installation process while maintaining the ability to optimize each subsystem during the manufacturing phase.
Solution Approach 2:
The drive system is designed as a modular assembly that can be segmented into functional modules (reduction gear module, motor module, electronics module) that are pre-assembled and tested together as a complete unit, then shipped and installed as one integrated package, reducing field assembly complexity.
2Adaptability or versatility
If the drive components are shipped separately, then storage and handling are more flexible, but transport volume and logistics complexity increase
Solution Approach 1:
By integrating all drive components into a single modular assembly, the patent reduces the number of separate packages from multiple to one, significantly decreasing total transport volume and simplifying logistics while maintaining storage flexibility through the compact integrated design.
3Ease of repair
If electronics are assembled independently on the torque tube, then electronics can be accessed separately, but the number of mobile elements and cables increases
Solution Approach 1:
The electronics are integrated into the modular drive assembly rather than being separately mounted on the torque tube. This consolidation reduces the number of separate mobile elements and eliminates the need for cables connecting fixed and mobile assemblies, while the modular design still allows for easy access and replacement of the entire electronics module.
4Ease of manufacture
If components are assembled in a non-compact way, then assembly is simpler, but transport efficiency and environmental impact worsen
Solution Approach 1:
The integrated modular design consolidates all components into a compact assembly that optimizes transport efficiency by reducing volume and weight, thereby lowering environmental impact during shipping, while the modular architecture maintains assembly simplicity through standardized interfaces and pre-assembly of subcomponents.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modular drive system reduces logistical complexities, enhances transport efficiency, improves assembly safety, and simplifies maintenance by allowing for easy disassembly and reassembly of components, while also reducing environmental impact and improving product sustainability.
Implementation Method 1
a worm screw-ring gear type reduction gear
Implementation Method 2
reduction gear system
Data Source
Figure 1~2
Figure 3
AI summary
The present invention comprises the following components: motor (2); reduction gear system (3), with an input, connected to the motor (2), and an output connectable to a torque element (12) of a solar tracker; electronics (4); and, preferably, power supply (5); optionally, a positioning system to detect the angular position of the solar tracker. The drive (1) is additionally characterised in that it comprises the different components, such as the motor (2), the reduction gear system (3) and electronics (4) in two or more modules (6, 7, 8), each in turn totally or partially delimited by one or more walls (15), where preferably a first module (6) is occupied by the motor (2), a second module (7), different from the first module (6), houses the electronics (4), preferably together with the power supply (5), and a third module (8) contains the reduction gear system (3). The invention simplifies manufacturing, factory and field calibration, logistics, assembly and maintenance, allowing faster disassembly, inspection and replacement of elements.